Pod-based grain popping apparatus and methods of popping grains

ABSTRACT

A grain-popping machine and associated pod-based popping method is disclosed. The grain-popping is configured to receive a pod. Each pod includes a plurality of cells, with each cell preferably containing a single grain kernel or seed, flavoring, and a cooking medium such as oil or shortening. In a preferred embodiment, the pod is loaded into the grain-popping machine through a slot so that it is held in position adjacent to a heating element. The heating element is activated to begin a popping sequence. When each grain kernel or seed in the pod reaches popping temperature, it absorbs the flavoring in its cell and ejects through the bottom of the pod, which can be weakened to ease ejection, into a bowl positioned in a receiving area of the grain-popping machine. The pod is then removed and disposed of.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 16/174,248, which is a continuation-in-part of U.S. patentapplication Ser. No. 15/960,383, filed Apr. 23, 2018, both of which areincorporated herein by reference in their entirety.

BACKGROUND

This invention relates to a grain popping apparatus and methods ofpopping grains. More particularly, the invention relates to pod-basedsystems and methods of preparing popcorn and other popped and puffedgrains that remedy the undesirable aspects of existing popping machinesand methods.

Popcorn is often made in bags pre-packaged with popcorn that are thenheated in a microwave, or in difficult-to-use machines that requiremanual loading of kernels, flavoring, and oils. Both solutions are lessthan ideal and achieve inadequate results. For example, it is difficult,if not impossible, to achieve even popping or flavoring of all kernelsin microwavable bags. A user must stand next to the microwave to listenfor particular popping patterns to try to guess when most of the kernelshave popped. As a result, microwaving popcorn results in a high numberof unpopped kernels, uneven flavoring, and burning. The interior of thebag is also covered in oil and flavoring, making it undesirable andmessy to eat directly from the bag. Portion sizes are also unnecessarilylarge, which often results in wasted, uneaten popcorn. Existingcountertop popping machines are complex to use, requiring manualmeasuring and loading of ingredients. They are difficult to cleanbecause several parts must be dismantled to clean the entire machineafter each use. Finally, because they use bulk flavoring and cooking ofkernels, flavor can be uneven and, like microwave popcorn, existingcountertop machines frequently result in unpopped kernels, unevenflavoring, and burning.

SUMMARY

The present invention resolves the myriad problems associated withexisting popcorn popping systems and methods. A grain-popping machine isdescribed that is configured to receive a pod. Each pod includes aplurality of cells, with each cell preferably containing a single grainkernel or seed, flavoring, and a cooking medium such as oil orshortening. In a preferred embodiment, the pod is loaded into thegrain-popping machine through a slot so that it is held in positionbelow a heating element. The heating element is activated to begin apopping sequence. When each grain kernel or seed in the pod reachespopping temperature, it absorbs the flavoring in its cell and ejectsthrough the bottom cover of the pod into a bowl positioned in areceiving area of the grain-popping machine. The pod is then removed anddisposed of.

The system and methods described herein therefore are easier to use andclean than existing methods of popping grains, avoid burning grains, andprovide even flavoring for all grains in the pod.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of one embodiment of a grain popping machineaccording to the present invention;

FIG. 2 is a top view of the grain popping machine of FIG. 1;

FIG. 3 is a perspective view of a grain pod according to one embodimentof the present invention;

FIG. 4 is a top perspective view of the grain pod of FIG. 3;

FIG. 5 is a bottom perspective view of the grain pod of FIG. 3

FIG. 6 is a perspective view of a grain pod and a heating element

FIG. 7 is a front and limited interior view of a grain popping machineaccording to an embodiment of the present invention;

FIG. 8 is a front and limited interior view of a grain popping machineaccording to another embodiment of the present invention;

FIG. 9 is a bottom perspective view of the grain pod of FIG. 3illustrating kernels individually exiting the grain pod

FIGS. 10A and 10B are top perspective and cross-section views,respectively, of the grain pod of FIG. 3;

FIGS. 11A and 11B are top perspective and cross-section views,respectively, of a grain pod according to another embodiment of thepresent invention;

FIG. 12 is a cross-section view of a grain pod according to anotherembodiment of the present invention;

FIG. 13 is a cross-section view of a grain pod according to anotherembodiment of the present invention;

FIG. 14 is another cross-section view of the grain pod of FIG. 13;

FIG. 15 illustrates a grain popping machine and method of popping grainsin accordance to another embodiment of the present invention;

FIG. 16 illustrates a grain popping machine and method of popping grainsin accordance to another embodiment of the present invention;

FIG. 17 illustrates a grain popping machine and method of popping grainsin accordance to another embodiment of the present invention;

FIG. 18 illustrates a perspective view of a grain pod insert or partialgrain pod according to another embodiment of the present invention;

FIG. 19 is a cross-section view of a grain pod according to theembodiment shown in FIG. 18;

FIG. 20 is a perspective view of a grain pod according to the embodimentshown in FIG. 18;

FIG. 21 is a bottom perspective view of a grain pod according to theembodiment shown in FIG. 18 with a corresponding heating element 602;

FIG. 22 is a top perspective view of a grain pod according to theembodiment shown in FIG. 18 with a corresponding heating element 602;

FIG. 23 is an exploded side view of a grain pod with separately formedcells.

FIG. 24 is a top perspective view of a docking tray of the grain podshown in FIG. 23.

FIG. 25 is a side view of the docking tray of FIG. 24 with cells.

FIG. 26 is a top perspective view of a clamshell type grain pod.

FIG. 27 is a side perspective view of a grain pod.

FIG. 28 is a side perspective view of half shell type grain pod.

FIG. 29 is another side perspective view of the grain pod shown in FIG.28 with grains positioned in the pod.

FIG. 30 is a side view of the grain pod shown in FIG. 28.

FIG. 31 is a side perspective view of a grain pod construction.

FIG. 32 is a top perspective view of a partial grain pod with ahoneycomb cell array.

FIG. 33 is a front and limited interior view of a grain popping machineaccording to an embodiment of the present invention;

DETAILED DESCRIPTION

Turning now to the drawings, in which like reference characters indicatecorresponding elements throughout the several views, FIG. 1 is aperspective view of a grain-popping machine 100 according to anembodiment of the present invention. Grain popping machine 100 has anupper chamber 102. Upper chamber 102 includes a pod slot 108, which canbe located at various positions on grain popping machine 100. FIG. 1illustrates two locations on grain popping machine 100 on which pod slot108 can be formed. While FIG. 1 illustrates two pod slots 108, it isunderstood that, in most embodiments, only one pod slot 108 would berequired. Thus, if the upper location of pod slot 108 is chosen, thelower location would generally not be included. Pod slot 108 can receivegrain pods of various shapes and sizes, as will be described in furtherdetail herein.

In the embodiment shown in FIG. 1, pod slot 108 is rectangular. The slotcould be in various other shapes in accordance with embodiments of thepresent invention. For example, the slot could be square, oval, orcircular. Pod slot 108 can also be formed in different lengths andwidths, regardless of the shape. In other embodiments, pod slot 108 isformed in different locations on upper chamber 102. For example, podslot 108 could be formed higher or lower on the front face of upperchamber 102 or could be positioned on the side of upper chamber 102. Inother embodiments, pod slot 108 is formed on the top surface of upperchamber 102. Pod slot 108 can be configured so that pods can beintroduced horizontally into the grain-popping machine 100. In otherembodiments, pod slot 108 is angled slightly upward so that pods areintroduced into grain popping machine 100 at an angle. Angling pod slot108 and interior guiding system for the pods allows for gravity to pullthe pod down to the desired position within grain popping machine 100,and can also isolate heating elements inside the grain-popping machine100 from exposure to the pod slot 108. Pod slot 108 can also be formedon the top of grain popping machine 100, and the pod can be insertedvertically, horizontally, or at an angle into the pod slot. Gravity orautomated mechanism can be used to pull the pod into the appropriateposition within upper chamber 102 in such embodiments, as explained infurther detail herein.

A pod dock, not shown, is preferably included inside upper chamber 102to receive grain pod 300 after the pod has been inserted into upperchamber through pod slot 108. When a grain pod has been inserted intoupper chamber 102 through pod slot 108, it is received in the pod dockeither through a user pushing the pod fully through the pod dock. Grainpopping machine 100 can signal to a user that the pod has been fullyreceived in the correct position in the pod dock through a variety offeedback mechanisms. For example, grain-popping machine can includehaptic or audio feedback, for example, a mechanical click or othersound. Visual feedback, for example, a light indicator, could also beprovided. Any combination of visual, audio, and haptic feedback can beused. Grain popping machine 100 can also include automatic means ofpositioning the pod properly in the pod dock. For example, an automatedguide can be included inside upper chamber 102. When a user inserts apod into pod slot 108, grain popping machine 100 senses that a pod hasbeen inserted and activates the automated guide, which mechanicallymoves the pod into the proper position in the pod dock by, for example,actuating a clamp that grabs the pod and moves it to the properposition.

In other embodiments, a door or tray is provided in upper chamber 102instead of pod slot 108. Upon activation by a user, the door or trayopens, exposing a pod dock. A user then inserts the pod into the poddock. When the door or tray is pushed fully closed, the pod dock will bein the proper location in upper chamber 102 below or above a heatingelement, as discussed in further detail herein. The pod dock may also bepositioned to the side of a heating element or in any other orientation,but is preferably positioned adjacent to a heating element. The door ortray may slide out horizontally from upper chamber 102, may swing openvertically, or may swing open pivoting on the lower or upper edges ofthe door.

Grain popping machine 100 also includes a dock area 103. A receiver 104is preferably provided with grain popping machine 100. Receiver 104 canbe a bowl or cup as shown in FIG. 1, and is designed to receive poppedgrains exiting from upper chamber 102, as will be described in furtherdetail. The receiver could be made out of various materials and can bedisposable or reusable. In some embodiments, receiver 104 is adisposable cup or bowl made of a paper or plastic material. In otherembodiments, receiver 104 can be formed of a ceramic or other type ofreusable material. Grain popping machine 100 further includes a base 106and an activation button 110. In a preferred embodiment, activationbutton 110 is centered along the front top edge of grain popping machine100. However, it is understood that activation button 110 can be locatedat other locations on grain popping machine 100. Activation button 110can physically displace when pressed, providing tactile feedback. Inother embodiments, activation button 110 can be a static button thatsenses touch and provides haptic, visual, or audio feedback whentouched. Preferably, grain-popping machine 100 is configured so thatactivation button 110 is the only physical button on the machine inorder to provide for streamlined operation. Grain popping machine 100can automatically turn on when a grain pod is inserted into pod slot108, or pressing the activation button 110 can turn on the machine. Ineither case, pushing activation button 110 after a grain pod has beeninserted into pod slot 108 can initiate a popping sequence.

Grain popping machine 100 may not feature any physical buttons and canboth power on and initiate a popping sequence by sensing, eithermechanically or through motion sensing technology, when a grain pod hasbeen inserted into pod slot 108. A physical button as described abovecan be included to power on the grain popping machine 100 and thepopping sequence can be initiated when a grain pod is inserted into podslot 108. Grain popping machine 100 can also trigger start up or poweron when a pod door opens or closes, or when a plunger is activated.

Grain popping machine 100 is operated by inserting into pod slot 108 apod of kernels or seeds of various types of poppable grains (corn, forexample) or puffable grains (rice, for example). Pod slot 108 is heatedinside upper chamber 102 by a heating element, as described in furtherdetail herein. Once the desired heat is reached, the kernels and seedsin the pod pop or puff and can be released from the pod in various ways.The popped grains exit upper chamber 102 through outlet 105 intoreceiver 104 for consumption by a consumer. As mentioned previously,various types of grains can be popped in grain popping machine 100. In apreferred embodiment, the grain to be popped in grain popping machine100 is popcorn, however, other types of grains can be popped or puffedin the machine, including quinoa, wheat berries, barley, amaranth,millet, sorghum, rice, and any other grain that pops or puffs at heat orby any other activation method. As used herein, a grain is an individualfruit, kernel, grist, or seed of a cereal or grass crop, whethercultivated or wild.

Grain popping machine 100 can provide lighting and other feedback toguide and optimize the user experience. For example, grain poppingmachine 100 can be provided with various lighting sources thatilluminate in different patterns, different colors, and at differenttimes to signify certain events in the operating cycle of grain poppingmachine 100 or to signal to a user that action is required. One type oflighting source that can be included on grain popping machine 100 is ahorizontal array 112 of light-emitting diodes stretching across thefront of grain popping machine 100, as illustrated in FIG. 1. Othertypes of lighting can be used in place of the light-emitting diodes, asone skilled in the art would appreciate. Activation button 110 and dockarea 103 can also be provided with light-emitting diodes or other lightsources. Grain popping machine 100 can also include a power switch,which can be provided at various locations on the machine.

As one example of a user experience guided by light sources on grainpopping machine 100, a user first switches the power switch to an onposition. Powering grain popping machine 100 on results horizontal array112 lighting up to display, for example, blue flashing lights thatindicate that grain popping machine 100 is running a self-diagnosticstart-up procedure. Horizontal array 112 can also progressivelyilluminate from left to right or right to left to indicate the progressmade during the self-diagnostic start-up procedure. Activation button110 may also light up in, for example, a white light. When theself-diagnostic procedure is complete, activation button 110 andhorizontal array 112 illuminate in green to signal to the user thatgrain popping machine 100 is ready for further interaction. Activationbutton 110 can flash in either green or white light to draw the user'sattention. Prior to a user pressing activation button 110, pod slot 108may be rendered inoperative to prevent insertion of a grain pod therein.A door may be provided to cover pod slot 108, with the door remainingclosed until the machine is ready to accept a grain pod. Other podreceiving methods can be utilized. For example, a slidable tray can beinserted into pod slot 108. The slidable tray can be automatically andmechanically operated by grain popping machine to slide out to receive agrain pod and slide back inside grain popping machine 100 once a pod hasbeen inserted into the appropriate slot on the slidable tray.

When the user presses the flashing activation button 110, pod slot 108becomes available to the user by, for example, an access door opening toprovide access to pod slot 108 for insertion of a pod or a slidable traysliding out of grain popping machine 100 to accept a grain pod. Pod slot108 can also be provided with light sources that illuminate green oranother color to indicate that grain popping machine 100 is ready for agrain pod to be inserted into pod slot 108. Once a grain pod is insertedinto grain popping machine, horizontal array 112 can flash orprogressively light from left to right to indicate that grain poppingmachine 100 is performing an analysis of the inserted grain pod prior tobeginning the popping sequence. This analysis can include checking toensure that the grain pod has been inserted properly, confirming thatthe grain pod is authentic and not a generic version of a grain pod, andanalyzing various coding included on the pod that can provide, forexample, popping instructions unique to the particular type of grain podinserted.

If the pod analysis confirms that the inserted grain pod is permitted toand ready to be popped, horizontal array 112 can present green lightingto indicate that the machine is ready to begin the popping sequence.Activation button 110 can also flash green to indicate readiness tobegin popping sequence. If receiver 104 is properly positioned in dockarea 103, a user can press activation button 110 to begin the poppingsequence. If receiver 104 is not positioned in dock area 103, a lightsource illuminating dock area 103 can flash or otherwise illuminate dockarea 103 and horizontal array 112 can flash to indicate to the user thatreceiver 104 should be placed in dock area 103. Once receiver 104 isproperly positioned, the light source in dock area 103 and horizontalarray 112 can show a solid, non-flashing color to indicate that themissing receiver 104 is now recognized. A weight or visual sensor can beincluded in dock area 103 to detect the presence or absence of receiver104. The user can press activation button 110 to begin the poppingsequence.

Once the popping sequence has begun, horizontal array 112 canprogressively light from left to right or right to left to indicate theprogress of the popping sequence. Horizontal array 112 can also blink inincreasing or decreasing frequency to indicate popping progress. Duringthe popping sequence, activation button 110 may display a red light,blinking or otherwise, which indicates that a user can press activationbutton 110 to cancel or pause the popping sequence. Once the poppingsequence has completed, horizontal array 112 may blink to indicate suchto the user. The light source in dock area 103 can also blink or displaya green light to indicate that receiver 104, containing the poppedgrain, can be removed. Horizontal array 112 can display blue lights,progressive, blinking, or solid, to indicate that grain popping machineis cooling. Once cooling has completed, all or some portion of the lightsources including on grain popping machine 100 can display a green lightindicating that the used grain pod can be removed and that grain poppingmachine 100 is ready to begin the next popping sequence. While the userinterface as described herein references specific colors and lightingpatterns, it is understood that the various lighting techniques,lighting combinations, and lighting colors described herein can be usedto indicate and stage the user experience.

FIG. 2 shows top view 200 of grain popping machine 100. As shown in FIG.2, the top 200 of grain popping machine 100 has heat and aroma vents202, formed therein. The vents 202 can take various forms. In apreferred embodiment, shown in FIG. 2, the heat and aroma vent 202 formsa circle on the outside of top 200. In other embodiments, the entire top200 of grain machine 100 could have venting slots formed therein. Vents202 can be formed in various shapes, for example, in the center of thetop or along the outer edge of top 200. Vents 202 could also be formedin addition to or in place of vent 202 on the sides of grain poppingmachine 100. Vent 202 allows heat to escape the upper chamber 102 andalso allows popcorn aroma to escape upper chamber 102. In someembodiments, filters are included inside grain popping machine 100,preferably between any heating elements included therein and vents 202.The filters reduce escaping aroma, which is useful in environments wherethere is a concern that the aroma of popped grains would be distracting.Insulation is also included inside upper chamber 102 in someembodiments. Including insulation reduces the considerable heatgenerating during popping by isolating the exterior of grain poppingmachine from heating elements and lowering the temperature of heatescaping through vents 202.

In a preferred embodiment, grain-popping machine 100 includes sensors(not shown) for sensing various parameters that could affect popping.For example, grain-popping machine 100 preferably includes anatmospheric pressure sensor that can provide feedback to the grainpopping machine 100 so that cooking times can be adjusted as necessarybased on the altitude at which a particular popping sequence isinitiated. Other sensors included in grain popping machine 100 includetemperature sensors for both ambient air and internal temperatures.Grain popping machine 100 can also include a processor, timer, database,and associated hardware for interpreting and acting on the informationprovided by the various sensors. The processor is preferably incommunication with a network allowing for remote updates to softwareprovided with the processor. This can include a wireless Internetnetwork or cellular network. The processor can include a storage mediumand machine-executable instructions stored thereon that cause the grainpopping machine 100 to perform various actions, for example, shorteningor lengthening popping time, based on pre-set instructions and takinginto account information about the surrounding environment gathered bythe various sensors. The processor can also include instructions thatcause the grain popping machine 100 to vary the heat applied to grainpod 300 by a heating element, the length of time heat is applied tograin pod 300, etc., based on indicators included on the pod or manuallyor remotely entered by a user. Examples of such indicators and methodsof communicating the indicators to grain popping machine 100 areprovided below. Grain popping machine 100 can also include audio sensorsand corresponding machine-readable instructions to monitor when and howmany kernels have popped and adjust the cooking temperature or timebased on that audio feedback. Machine learning and artificialintelligence programs can be used to optimize the various sensors.

FIG. 3 shows a preferred embodiment of a grain pod 300. Grain pod 300includes kernels or seeds of one or more types of grains, as describedpreviously. Although not shown in FIG. 3, in a preferred embodiment thegrains are contained in individual cells inside grain pod 300. Grain pod300 has a top cover 302, a bottom cover 306, and a sidewall 304. Grainpod 300 can be formed of various materials. In a preferred embodiment,grain pod 300 is formed of a high temperature tolerant plastic. Inalternate embodiments, grain pod 300 can be formed of various metals,preferably a lightweight metal, for example, aluminum. Grain pod 300could also be formed of a non-flammable, paper-based material or anyother natural or manufactured material that is resistant to hightemperatures. In one embodiment, grain pod 300 is between 7 and 12millimeters tall as measured from the top cover 302 to bottom cover 306.In other embodiments, grain pod 300 is either 9 or 10 millimeters tallbetween top cover 302 and bottom cover 306. Grain pod 300 can also beformed with additional insulating material between millimeters tallbetween top cover 302 and bottom cover 306. The insulating material canaid in stacking the pods for storage and shipment and helps to reducethe heat transmitted to the outside of grain pod 300 when it is removedfrom grain popping machine after a popping sequence has concluded. Grainpod 300 can also be formed with extended tabs on its periphery to aid inhandling grain pod 300.

Top cover 302 of grain pod 300 is preferably formed of a heat conductivematerial. In a preferred embodiment, the top cover 302 is formed of athin aluminum material or other heat conductive material. Although grainpod 300 is shown in a circular shape, it is understood that various podshapes could be used to achieve similar results. For example, grain pod300 could take a square or oval or rectangular form instead of thecircular form showed in FIG. 3. Grain pod 300, as shown in FIG. 3, alsoincludes a channel 308 between a raised outer lip 310 and an inner wall312. Both top cover 302 and bottom cover 306 are sealed to grain pod 300in order to seal in the grain kernels, flavoring, cooking medium (forexample, cooking oils, shortening, lard, etc.) and other ediblematerials contained inside grain pod 300, as will be shown in furtherdetail herein. Various methods can be used to seal top cover 302 andbottom cover 306 to grain pod 300. For example, the covers can be sealedto grain pod 300 by friction welding, including horizontal frictionwelding, sonic welding, radio frequency (RF) welding, application ofheat, horizontal scrubbing, gluing, folding connecting taps, orspindling, among other methods known in the art, can be used.

Grain pod 300 can include numerous combinations of poppable or puffablegrains and various flavorings, or can include kernels or seeds of onlyone particular type of grain. In preferred embodiments, grain pod 300includes text, coloring, or graphics, or a combination thereof, toindicate the particular grain or grains inside the grain pod 300 and theflavoring and cooking medium included therein. In other embodiments,grain pod 300 includes a variety of grains, with each grain includedhaving the same flavoring or with different grains in the grain pod 300having different flavorings. Although not shown in FIG. 3, grain pod 300may include machine-readable indicators that can communicate to grainpopping machine 100 the type of grain or grains in grain pod 300, theflavor or flavors included in grain pod 300, and the type or types ofoil, shortening, or other cooking medium included in grain pod 300. In apreferred embodiment, grain pod 300 includes a bar code, QR code, orother type of machine-readable coding pattern that serves as themachine-readable indicator discussed previously. In such embodiments,grain popping machine 100 includes a reader (not shown) for reading thecoding pattern included on grain pod 300. The reader can be positionedinside upper chamber 102 or at the entry to pod slot 108. In otherembodiments, the reader can be positioned on the outside of grainpopping machine 100 so that a user can scan the code on the reader priorto inserting grain pod 300 into grain popping machine 100. The code canbe printed on the grain pod 300, can be a textured pattern elevated offthe surface of grain pod 300, or could simply be a color pattern on thegrain pod. It is understood that the machine-readable code can bepositioned anywhere on grain pod 300. However, in a preferredembodiment, the machine-readable code is formed on the bottom of grainpod 300.

In other embodiments, grain pod 300 includes spaced notches orindentations along the periphery thereof that serve as an indicator tograin popping machine 100 of the type of grain or grains in grain pod300, the flavor or flavors included in grain pod 300, and the type ortypes of oil, shortening, or other cooking facilitator included in grainpod 300. The notches or indentations can be provided on grain pod 300 ina particular number, with specific distances between each notch orindentation, or in different widths, depths, or shapes, all of which, ora combination of which, can serve as the indicator discussed previously.Similar to the previous embodiment, grain-popping machine 100 caninclude a reader configured to read and interpret the machine-readablecode formed by the notches or indentations, either mechanically,optically, or using any of a variety of sensing methods.

In still other embodiments, grain pod 300 could be formed in differentshapes, thicknesses, diameters, widths, and lengths. Small variations inthese variables can indicate to a reader on or inside grain poppingmachine 100 the type of grain or grains in grain pod 300, the flavor orflavors included in grain pod 300, and the type or types of oil,shortening, or other cooking facilitator included in grain pod 300.Alternately, or in addition to, using machine-readable indicators asdescribed above, grain pod 300 can be formed with a simplehuman-readable code thereon. A human-readable code could also beprovided on the packaging of a group of grain pods 300 and recorded at acentral website or user guide provided with grain pod 300. In suchembodiments, grain-popping machine 100 includes a user interface thatallows a user to enter the human-readable code. Alternately, a mobiledevice application or remote control is provided to allow a user tointerface with grain popping machine 100. The mobile device applicationor remote control could allow the user to perform a variety offunctions, including powering on/off grain popping machine 100,initiating a popping sequence, emergency power off, indicating the typeof grain or grains in grain pod 300, the flavor or flavors included ingrain pod 300, and the type or types of oil, shortening, or othercooking facilitator included in grain pod 300, ordering additional grainpods 300, submitting a help request, submitting a service call, etc.

FIG. 4 shows an exploded view of grain pod 300 with the top cover 302hovering above the grain pod 300. As shown in FIG. 4, numerous cells 402are formed on the interior of grain pod 300. Each cell 402 is designedto hold a kernel or seed of a grain, for example, corn. In addition tothe kernels, cells 402 hold flavoring and a cooking medium to facilitatepopping of the corn when exposed to heat for a prolonged period. Asshown in FIG. 4, cells 402 are formed in a generally honeycombed patternat even distances from each other. As will be described in otherembodiments herein, cells 402 could also be formed in circular, square,oval, polygonal, or other shapes. FIG. 4 also shows cell walls 404,which separate cells 402. In other embodiments, cell walls 404 could bethinner or thicker than shown in FIG. 4. In addition, grain pod 300could be formed without cells and cell walls and instead have one layerof kernels or seeds distributed roughly equally across the interiorsurface area of grain pod 300. For example, grain pod 300 could beformed with a flat chamber therein to hold kernels in a single layer ormultiple layers inside grain pod 300. During manufacturing, grainkernels are placed within cells 402 along with flavoring and cookingmedium and any other desired ingredient to enhance the flavor,appearance, or popping qualities of the grain. Once the kernels areinside cells 402, the top 302 is sealed onto grain pod 300.

In a preferred embodiment, grain pod 300 includes approximately 1.5 to3.5 tablespoons of grains or kernels, with each cell including a singlekernel or grain. More preferably, each grain pod 300 includes 2.5tablespoons of grains or kernels, with that result that each poppingsequence produces between 4.5 and 5 ounces of popped grains. However, inother embodiments larger or smaller pods containing additional or fewerkernels or grains can be provided while still retaining the benefits ofpod-based popping.

FIG. 5 shows an exploded view from below grain pod 300. As shown in FIG.5, bottom cover 306 has not yet been affixed to grain pod 300. Bottomcover 306 can be formed of a variety of materials. In a preferredembodiment, bottom cover 306 is formed of a high temperature compatiblepaper that will allow for easy exit of popped kernels from cells 402. Inother embodiments, bottom cover 306 is formed of a lightweight metalfoil, preferably aluminum foil. As described in further detail herein,bottom cover 306 can be formed with perforations or other mechanicallyweakened points to facilitate escape of popped kernels from grain pod300. Bottom cover 306 could also be formed of a material that weakens asit gets hotter so that the material is weakened once grains reach acertain temperature, thereby allowing the grains to escape from cells402. As shown in FIG. 5, the sidewall 304 of grain pod 300 may have aninner lip 502 formed on the bottom side thereof. Grain pod 300 may alsoinclude a notch 504 on the bottom side of sidewall 304. The mechanicaluse of inner lip 502 and bottom 504 will be explained in further detailherein.

FIG. 6 shows a heating element 602 positioned above a grain pod 300.Heating element 602 can be formed of a metal ceramic polymer orcomposite material. Heating element 602 could also be formed of acombination of any of the previously mentioned types of heatingelements. In a preferred embodiment, heating element 602 is formed of ametal material such as nichrome. In other embodiments, heating element602 can be formed of metal such as kanthal or cupronickel. Heatingelement 602 may also be formed of an etched foil. While heating element602 is shown as a solid circular slab in FIG. 6, in some embodiments ofthe invention, heating element 602 could be formed as a collection ofwires, ribbons, or strips. Heating element 602 can be covered orsandwiched between layers of materials selected from the mica group ofsheet silicates to provide insulation. Heating element 602 can also beor include cartridge heaters. Heating element 602 can be provided in avariety of orientations relative to grain pod 300, i.e., below, above,side-by-side, at an angle etc., provided that heating element 602 is inclose enough proximity to grain pod 300 to transfer heat thereto.

Heating element 602, regardless of the material from which it is made,can also be formed in different shapes. For example, it can be formed ina square shape, a rectangular shape, a polygon shape, oval shape, or anynon-symmetric shape, and can be formed in various thicknesses.Preferably, the shape of heating element 602 matches that of grain pod300. This configuration allows for even heating across the surface ofgrain pod 300, resulting in more even popping of the kernels or grainstherein. In addition, heating element 602 could be formed to wrap aroundgrain pod 300 so that grain pod 300 nests within heating element 602, ora second heating element could be provided underneath grain pod 300 forall or a portion of the popping sequence. In such embodiments, thesecond, lower heating element could be automatically removed at adesignated time or point during the popping sequence so as not tointerfere with the popped kernels or grains as they exit grain pod 300.The second heating element can be formed with holes aligning with thecells 402 of grain pod 300. When the second heating element is formedwith such holes, it can be left in place for the duration of the poppingcycle, as the popped grains can pass through the holes in the secondheating element and into the receiver 104. It is also understood thatmore than two heating elements can be used, and that heating elementscan be applied from a variety of distances from grain pod 300 and can bepositioned at a variety of angles to the grain pod 300.

When two heating elements are included, they can be positioned in aclamshell configuration, such that one or both of the heating elementscan pivot at an angle to the other heating element at one or more stagesof the popping process. When a clamshell configuration is used, the twoheating elements can be physically hinged together or can be held inplace relative to each other by other mechanical or vacuum structuresinside grain popping machine 100. For example, when the clamshellconfiguration is implemented such that the two heating elements andgrain pod 300 are positioned horizontally within grain popping machine100, the top heating element can pivot upwards from one point or side toan angle relative to the position of the bottom housing element when thegrains are sufficiently heated to a popping temperature or closethereto. When this configuration is used, the popped kernels exit fromthe top of grain pod 300, deflect off the bottom surface of the topheating element, and down into the receiver 104. Alternately, the bottomheating element in such a configuration can pivot while the grain pod300 and the top heating element remain in a roughly horizontal position,such that the kernels can exit down from the grain pod 300 and intoreceiver 104. Similarly, the two heating elements and grain pod 300 canall be positioned at an angle relative to the surface on which grainpopping machine 100 sits, and one or both of the heating elements canhinge open when the kernels have reached a desired temperature or whenheat has been applied for a pre-determined time.

Heating element 602 can also be formed with cavities corresponding toand aligning with the cells 402 of grain pod 300. The cavities are of asize and shape that allow each cell 402 to partially or completely nestwithin a cavity formed in the surface of heating element facing grainpod 300. This configuration applies heat to the grains inside cells 402from a variety of angles instead of only from above or below. Heatingelement 602 with cavities can be positioned underneath or above grainpod 300. When heating element 602 with cavities is used, grain pod 300is preferably formed such that the cells 402 protrude at least partiallyfrom the body of the pod. One example of such a pod construction isdetailed herein with respect to FIG. 12. When heating element 602 withcavities is positioned above the grain pod 300 inside grain poppingmachine 100, grain pod 300 is preferably formed such that the cells 402protrude upward instead of downward when positioned inside grain poppingmachine 100.

In other embodiments, heating element 602 is formed of ceramic heatingelement such as molybdenum disilicide or various PTC ceramic elements.Heating element 602 could also be formed of polymer PTC heating elementsincluding PTC rubber materials. Heating element 602 may also be aradiative heating element, such as a high-powered incandescent lamp orother type of radiant or infrared heating elements, for example, an R40reflector lamp or similar lamps. In operation, heating element 602 isplaced directly above or in contact with top cover 302 of grain pod 300.As heating element 602 heats to an appropriate temperature depending onthe type of grain and other factors, the kernels inside grain pod 300heat, eventually heating to a temperature at which the specific grainpops and the grains then exit the grain pod 300. In some embodiments, aconductor material, for example, copper, is positioned between heatingelement 602 and grain pod 300. The conductor material ensures that heatfrom heating element 602 is evenly applied across the top surface ofgrain pod 300, and also helps moderate the speed at which maximumcooking temperature is reached.

Positioning heating element 602 above grain pod 300 and configuringgrain pod 300 so that popped grains escape grain pod 300 through thebottom cover 306 provides several advantages. For example, allowing thepopped grains to exit the bottom cover 306 directly into receiver 104greatly reduces the surface area of grain popping machine 100 thatrequires cleaning. Only the relatively small portion of upper chamber102 between the bottom of grain pod 300 and receiver 104 is contacted bypopped grains. That portion of upper chamber is easily reached forcleaning without disassembling grain popping machine 100. In contrast,in prior art systems using free loaded grains instead of pods, theheating element was placed below the grains, so that when the grainspopped they would exit up and around a heating element to fall into abowl. In doing so, the grains contact almost the entire interior surfacearea of a machine, which must then be dismantled regularly for detailedcleaning and disinfecting. In addition, positioning grain pod 300 belowheating element 602 ensures that no popped grains fall back into or ontop of grain pod 300 after being popped, thereby reducing the risk ofovercooked or burnt kernels, which negatively affect a user'sexperience. Popped grains exit their particular cell 402 immediatelyupon popping and are removed from the area of heating element 602 toreceiver 104, reducing the chance of overcooking or burning andaccommodating for slight variances in popping times between individualgrains.

FIG. 7 shows grain-popping machine 100 with heating element 602 andgrain pod 300 positioned within upper chamber 102. The circular openingshown in FIG. 7 is included as a window to the inside of upper chamber102 for purposes of illustration. In preferred embodiments, only podslot 108 is formed on the exterior of upper chamber 102 so that heatingelement 602 and grain pod 300 are not visible from the exterior of upperchamber 102. As shown in FIG. 7, heating element 602 is positioneddirectly above, and in some embodiments, in contact with the top ofgrain pod 300 inside upper chamber 102. As heating element 602 heats thekernels inside grain pod 300 to a target temperature for a prolongedtime, both of which vary depending on the type of grain used, flavoring,cooking medium, and other environmental conditions such as pressure andaltitude, the kernels pop and the popping of the kernels causes them toeject from the bottom of grain pod 300 through bottom cover 306, out ofupper chamber 102, and into receiver 104. By having the kernels exitgrain pod 300 through the bottom, the surface area of upper chamber 102contacted by popped grains and liquids is kept at a minimum because thepopped kernels do not contact any of the other surfaces of upperchamber, which reduces cleaning time and difficulty and makes grainpopping machine 100 operate more cleanly than prior art machines. Afterpopping, grain pod 300 is ejected from grain popping machine 100 and canbe disposed of in a trash receptacle so that the machine is immediatelyable to receive another grain pod. The popped kernels can be removedfrom the grain-popping machine by removing receiver 104, which can serveas a bowl for serving the popped kernels. Preferably, each grain pod 300includes only enough popped kernels to form a single serving of theparticular popped grain chosen. As detailed above with respect to FIG.1, the popped kernels exit upper chamber 102 through outlet 105, whichis open to the bottom of grain pod 300.

Ideal cooking times and temperatures for a particular grain pod 300 varybased on the types of grains, flavorings, and cooking medium included incells 402, as well as ambient temperature, pressure, altitude, and othervariables. As detailed above, grain popping machine 100 can include aprocessor and associated hardware and software to account for thesevariables and automatically alter cooking times and temperaturesaccordingly. However, in preferred embodiments, heating element 602 isheated to between approximately 325 degrees Fahrenheit and 600 degreesFahrenheit, and more preferably to a constant temperature of 400 degreesFahrenheit, with a variance of plus or minus 10 degrees. In otherembodiments, heating element 602 can vary temperatures during thepopping sequence to achieve a max temperature earlier or later in thesequence.

Temperature sensors can also be provided to directly sense thetemperature inside cells 402 and the processor can include instructionsto dynamically alter the temperature of heating element 602 during apopping sequence to optimize the temperature reached by grains in thecells 402 and ensure that no grains are overcooked or burned. Humiditysensors can also be included in grain popping machine 100, either tomeasure ambient humidity outside or inside upper chamber 102, or morepreferably to measure humidity inside cells 402 to determine whether apredetermined cooking time and temperature should be altered to optimizepopping of grains in a particular grain pod 300. In a preferredembodiment, the entire popping sequence is completed in less than onehundred and twenty seconds. More preferably, the popping sequence frominsertion of grain pod 300 to the time at which all grains have poppedand entered receiver 104 is completed in approximately sixty seconds, orless. In other embodiments, the popping sequence is completed inapproximately one hundred and eighty seconds, that is, one hundredeighty seconds plus or minus thirty seconds to accommodate forvariables.

FIG. 8 shows an alternate embodiment of grain popping machine 100. Inthis embodiment, heating element 602 is positioned below grain pod 300.The circular opening shown in FIG. 8 is included as a window to theinside of upper chamber 102 for purposes of illustration. As heatingelement 602 reaches the temperature to pop the kernels in grain pod 300,the kernels pop and exit the grain pod 300 and are funneled back down bygravity through outlet 105 and into receiver 104, as shown by the arrowsin FIG. 8.

Popping grains requires high temperatures, which presents issues for acountertop consumer device. Various methods are contemplated to addressthis safety issue. For example, whatever configuration of heatingelements is chosen, grids or gates can be provided inside grain poppingmachine 100 to prevent children from contacting the surface of theheating elements if they insert their fingers through pod slot 108 orany other opening to the interior of grain popping machine 100. A safetyinterlock can also be provided such that a door to pod slot 108 or otherpod insertion opening on grain popping machine 100 can only be openedwhen a pod is being inserted, with no extra space for insertion offingers or other body parts. Child proof safety switches can also beprovided to prevent access to or operation of grain popping machine whenthe safety switch has not been manipulated into a position that allowssuch access or operation. All openings to the interior of grain poppingmachine 100 can also be automatically disabled when the temperatureinside the machine is above a safe level, and the opening can beautomatically made functional again once the temperature has droppedbelow a safe level. Various methods can be used to more quickly coolgrain popping machine 100 and heating elements 602 after a poppingcycle. For example, heat sinks or heat pipes can be used to remove heatfrom heating elements 602. Cooling fluid can also be circulated over oraround heating elements 602 to accelerate cooling. Because grain poppingmachine 100 may be heavier towards the top than at the bottom, a heatsink can be positioned under the receiving tray to balance the weightdistribution while providing cooling.

FIG. 9 illustrates popped kernels 902 exiting through bottom cover 306of grain pod 300. The orientation of heating element 602 above grain pod300 is similar to the orientation shown in the grain-popping machine ofFIG. 7. Because each cell 402 contains a single kernel, each kernel isfree to pop when that particular kernel reaches the appropriatetemperature for the particular kernel. This allows for slight variationsin the popping time for different kernels in the same grain pod 300 sothat kernels that might pop earlier than other kernels are not burned bybeing kept in contact with a heat source after popping.

FIGS. 10A and 10B illustrate a preferred embodiment of grain pod 300. Asshown in FIG. 10A, grain pod 300 is formed in a generally circular orcylindrical shape with cells 402 and cell walls 404. The cells of thegrain pod shown in FIG. 10A are formed in a hexagonal shape similar to ahoneycomb. In a preferred embodiment, the cells 402 shown in FIG. 10Aare sized to hold a single grain seed or kernel in addition to anydesired flavoring or cooking medium. As the kernels heat and pop, theyabsorb the flavoring placed in the cells. The cooking medium can be anoil infused with a flavor or combination of flavors, or dry flavoringcan be added separately to the cell prior to sealing. Instead of or inaddition to providing flavoring inside each cell 402, flavoring can beadded as or after the popped grains exit cells 402. The post-exitflavoring can be achieved by a misting or spraying device that ejectsflavoring, either dry or liquid, onto the popped grains as they exit thepod or after they have been received in receiver 104. The misting orspraying device can be automatic, i.e., it can operate without userintervention, or controls can be provided to allow a user to active thedevice to add the desired flavoring. Flavoring shakers or packets canalso be provided separately with grain popping machine 100 to allow auser to customize flavoring.

FIG. 10B shows a cross-section of FIG. 10A, showing the vertical shapeof cell walls 404. As shown in FIG. 10B, each cell is formed so that itis narrower towards the top cover 302 of grain pod 300 and becomes widermoving towards bottom cover 306. As the kernel is heated by heatingelement 602 and eventually reaches its popping temperature, the kernelexpands, or pops. As the kernel expands, the shape of cells 402 in FIG.10B apply pressure to the portion of the kernel towards top cover 302,thereby ejecting the popped kernel through the bottom cover 306 of grainpod 300. The change in diameter or width of cells 404 from the top ofgrain pod 300 to the bottom of grain pod 300 can be altered to achievemore or less pressure on the kernel in the pod upon popping. Thevertical angle of cell walls 404, shown in FIG. 10B, are preferablybetween 1 and 45 degrees. More preferably, the angle is between 6 and 16degrees, and most preferably approximately 9-11 degrees. The angling ofcell walls 404 direct much of the energy created by a popping graintowards the bottom cover 306 to increase the pressure on the materialforming bottom cover 306. In addition to or in place of angling, theshape of the cells can include a conical section, a conical section withthe flat bottom, a parabola with the wider portion positioned towardbottom cover 306, or any combination of the above. The angling can bereversed for grain pods where exit through top cover 302 is desired.Cells 404 can also be formed to have the same, or substantially thesame, that is, within acceptable manufacturing variations, diameters andwidths from the top of the grain pod 300 to the bottom of grain pod 300.

FIG. 10B also illustrates an alternate embodiment of sidewall 304. Asshown in FIG. 10B, raised lip 310 of sidewall 304 extends upward fromthe top of grain pod 300. Sidewall 304 is formed with a notch 1002towards the bottom thereof. When grain pods 300 are stacked in a packagecontaining multiple grain pods, upper lip 310 rests inside notch 1002 tosecure the stacked grain pods together and to provide a resting surfacefor the pods so that the top and bottom covers of grain pods 300 stackedtogether in a package remain slightly apart from each other. This helpsprevent breakage or damage to of the top and bottom cover duringshipping, delivery, and storage of grain pods 300.

FIGS. 11A and 11B illustrate another embodiment of grain pod 300. Asshown in FIG. 11A, the cells 402 are circular when viewed from the top.Cell walls 404 divide the cells 402. FIG. 11B shows a cross-section ofthe grain pod 300 illustrated in FIG. 11A. As with the grain pod 300shown in FIGS. 10A and 10B, the cells 402 of the FIG. 11B grain pod arewider towards the bottom of the grain pod than they are at the top. Thecell walls 404 are slightly curved so that each cell is generally in theshape of an inverted U with the open part of the U facing the bottom ofgrain pod 300 and being wider than the diameter of the bottom of the U,which is positioned near or in contact with top cover 302 of the grainpod. As with the embodiments shown in FIGS. 10A and 10B, the grain pod300 shown in FIGS. 11A and 11B feature a raised upper lip 310 and anotch 1002 in the bottom of the sidewall. These features, as describedabove, aid in stacking packaging and delivering the grain pods.

FIG. 12 illustrates a cross-section of another embodiment of grain pod300. The grain pod shown in FIG. 12 is similar to the previouslydescribed grain pods, with the exception that the cells areapproximately half as high as the cells of the previous embodiments. Asa result, the grains or kernels placed in each cell protrude, at leastpartially, from the cell out from the bottom of the grain pod 300. Thegrains are still sealed into the cells by a bottom cover, but in thisembodiment the bottom cover is, preferably, a flexible membrane 1204that holds the grain kernels in their cells 402 and seals each cell offfrom other cells 402, but that conforms to the shape of the kernelsprotruding from the cells 402. The grain pod 300 shown in FIG. 12 alsofeatures an extended inner lip 1202, which extends slightly beyond thelowest point of flexible membrane 1204. The extended inner lip 1202rests on the top of the sidewall so that when the pods are stacked, themembrane cover 1204 does not make contact with the top cover 302 ofgrain pod 300. In doing so, the extended inner lip 1202 preventsunwanted tearing or damage to the flexible membrane 1204 or top cover302 during packaging, shipment, delivery, and storage. Configuring thecells so that they are less deep than the height required to accommodatea full kernel aids in ejecting the kernels from the cells as they pop.Because they are already partially out, the pressure created by the opencells facilitates the kernels breaking through the flexible membrane1204 as they pop. Ideally, fifty percent or more of the kernel protrudesfrom cells 402. Configuring grain pod 300 such that between sixty andseventy-five percent of the kernel protrudes from cell 402 further aidsejection of the kernels from the cells and can also provide heatingadvantages, as discussed elsewhere herein. The cells 402 may also beshaped so that they have a wider diameter towards the flexible membrane1204 of grain pod 300 than towards the top cover 302. It is understoodthat various cell shapes and sizes can be used with the flexiblemembrane shown in 1204, and that various materials and manufacturingmethods, as discussed elsewhere herein, can be used to form the grainpod 300 illustrated in FIG. 12.

FIG. 13 illustrates another embodiment of grain pod 300. As shown inFIG. 13, the cells 402 have a bulbous shape, but still with the topportion of the cells 402 closest to top cover 302 being narrower thanthe bottom portion of cells 402. Again, as in previous embodiments, thisencourages the kernel to exit the pod downward as it pops. Also shown inFIG. 13 are a series of perforations or weakened areas 1306 in thebottom cover 306 of grain pod 300. In a preferred embodiment, theseperforations allow the bottom cover 306 to tear as the kernel pops andexits the bottom cover 306. As shown in FIG. 14, for example, the bottomcover is easier to pierce by the kernel than if it did not have aperforation. Embodiments of these weakened areas will be described infurther detail with respect to FIG. 14. Also shown in FIG. 13 is analternate embodiment of the stacking and mating systems describedearlier. As seen in FIG. 13, inner lip 502 extends downward, creating amale mating end, and channel 308 on the top portion of grain pod 300 isadapted to receive the inner lip 502.

FIG. 14 illustrates various methods of weakening bottom cover 306 ofgrain pod 300 so that the kernels can more easily break through thebottom cover 306. The kernel designated as 1404 has exited through thebottom cover 306. The portion of bottom cover 306 next to the cell thatkernel 1404 is exiting from has been weakened, either mechanically or byother means, approximately in the center of the cell 402, so that whenthe kernel breaks through bottom cover 306, the bottom cover 306 splitsapproximately in the middle of the cell and the edges of the bottomcover 306 remain attached to the top of cell walls 404 so that thematerial that forms the bottom cover 306 does not exit into the receiver104. The material of the bottom cover 306 thereby stays attached to thegrain pod 300 instead of falling into the receiver 104 with the poppedgrain. Similar results are achieved if a flexible membrane 1204 is used.

In another embodiment, as shown with reference to kernel 1402 in FIG.14, the bottom cover 306 can be weakened, for example, by physicalperforations or other weakening, along only one side or portion of acell 402. In operation, this is similar to the perforation describedwith respect to kernel 1404, except that instead of the ripped pieces ofthe bottom cover 306 remaining attached to all sides of the cell walls404, the bottom cover 306 may be held to only a portion of the top ofcell walls 404. For example, one half of the bottom cover correspondingto a particular cell 402 may remain attached to the cell walls 404,while the other half may be pre-perforated or otherwise weakened so thatit breaks off, easily allowing the kernel to escape when it pops.Although thus far discussion of weakening the bottom cover 306 hasfocused mostly on physical perforation of the bottom cover 306, that ismerely one example of potential ways to weaken portions of the bottomcover 306 to facilitate escape of a kernel. Instead of perforating atparticular locations, the bottom cover could be formed of a thinnermaterial at those particular locations or it could be formed of adifferent material at those locations that weakens faster than the mainbody of bottom cover 306 as temperature increases. In other embodiments,the material that fastens bottom cover 306 to the top of cell walls 404may be varied at certain locations in order to facilitate breaking ofthe bottom cover 306. For example, a portion of the material bondingbottom cover 306 to the cell walls 404 could be a different bondingmaterial than other portions. The bonding material in the weakenedportions might be chosen so that it melts and creates a weaker bond athigher temperature than other portions of the bonding material toachieve similar results to perforation or mechanical weakening. Forembodiments that feature mechanical perforation, or some other type ofmechanical weakening of bottom cover 306, various methods can be used toachieve that perforation. For example, the bottom cover 306 could bepre-perforated during manufacturing and before shipment. In alternateembodiments the grain-popping machine 100 can be formed with amechanical perforator or weakener inside, so that when a user insertsgrain pod 300 into grain popping machine 100, the bottom cover 306 ofgrain pod 300 is perforated in grain popping machine 100 or duringinsertion into the grain-popping machine 100.

FIGS. 15-17 illustrate alternate embodiments of grain popping machine100 according to the present invention. In FIG. 15, grain pod 300 ispositioned inside grain popping machine 100 so that it is above heatingelement 602 instead of below heating element 602. Grain pod 300 isflipped from the configuration shown in previous embodiments where thekernel exits from the bottom of grain pod 300. In the embodiment shownin FIG. 15 of the grain pod 300, the kernels exit towards the top of thegrain-popping machine 100 instead of straight down. As heating element602 heats the kernels within grain pod 300 to the appropriatetemperature for that particular grain, the grains would pop; exiting thegrain pod 300, and gravity causes the popped kernels to fall down intoreceiver 104, as shown in step 1504. In the embodiment shown in FIG. 15,a fan, preferably a silent fan, could be used to help the kernels exitthe grain pod 300 and filter down to receiver 104. Once the receiver 104is full of the popped grains, it can be removed from dock 103 as shownin step 1506.

FIG. 16 shows another embodiment of grain popping machine 100. In theembodiment in FIG. 16, grain pod 300 is positioned inside the machineabove heating element 602 instead of below. As shown in step 1602, grainpod 300 is configured so that as the grains pop, the grain pod expandsand the sidewall 304 of the grain pod expands. Once the grains havepopped, the heating element is mechanically removed, preferablyautomatically, from underneath grain pod 300. The bottom of grain pod300 is pulled with heating element and the popped kernels are pulled bygravity into the receiver 104 and can then be removed from the dock 103,as shown in step 1608.

FIG. 17 shows another embodiment of grain popping machine 100 accordingto the present invention. In FIG. 17, grain pod 300 is inserted intograin popping machine 100 so that it is positioned above heating element602. As heating element 602 heats the kernels in grain pod 300 to thepopping temperature, grain pod 300 expands into a bucket shape. Thebucket formed by the grain pod 300 in this embodiment serves as areceiver 104 and grain pod 300 itself, in its bucket shape, can beremoved from grain popping machine 100 for serving the popped grains. Asshown in step 1706, heating element 602 is mechanically moved, in someembodiments, from the bottom of grain pod 300, and a cooling fan coolsthe expanded grain pod 300 so that it is safe for handling by aconsumer. It is understood that grain pod 300 shown in FIG. 17 couldtake various shapes on expansion and is not strictly confined to theshape shown in FIG. 17.

FIG. 18 illustrates a portion of a portion of a grain pod insert 401.Grain pod insert 401 is preferably formed of a thermoplastic polymer,although other materials compatible with use in the food industry can beused. Various types of polymers are contemplated for grain pod insert401, including natural polymers and synthetic thermoplastic polymers,including but not limited to nylon. Additives can be included in thepolymers used to form grain pod insert 401.

Grain pod insert 401 includes cells 402 and cell walls 404 similar tothose described with respect to other embodiments of the presentinvention. As shown in FIG. 18, cells 402 are formed with a generallycircular cross section and a rounded bottom. However, it is understoodthat cells 402 could be formed in a variety of cross-sectional shapes,including, but not limited to, the hexagonal and square cross-sectionalshapes described with respect to other embodiments herein. Cells 402could also be formed with a flat bottom instead of the rounded bottomshown in FIG. 18. Because grain pod insert 401 is preferably formed of apolymer, e.g., a nylon material, it can be formed by heating a flatsheet of polymer to a temperature at which the polymer can be stretchedinto the form shown in FIG. 18 by application of mechanical force to thepolymer sheet. For example, grain pod insert 401 can be formed partiallyor completely through the use of thermoforming. Grain pod insert couldalso be formed by directly applying the polymer sheet to an array ofgrains. When this method is used, the polymer sheet stretches closelyaround the shape of each individual grain. When top cover is appliedover the stretched polymer sheet, closed cells 402 are formed around thegrain, with little, if any, airspace within the cells. Vacuum sealingcould be used to remove all air from cells 402 formed in this manner.Forming grain pod insert 401 in this manner simplifies manufacturing. Inaddition, polymers such as nylon are known to weaken as they are heated,and through polymer compounding, which involves mixing or blendingpolymers and additives to alter certain properties of the resultingmaterial, the polymers can be engineered to reach a desired weakness atdesired temperatures. As a result, a grain pod 300 constructed withgrain pod insert 401 does not require a bottom cover 306. The cells 402of grain pod insert 401 are closed at the bottom portion thereof, whichserves to retain grains, flavoring, and cooking medium within the cells402. The polymer forming grain pod insert 401 is engineered to weaken tonear breaking point at the ambient temperature at which grains containedin cells 402 will being to pop. As a result, the popping grains caneasily break through the bottom of cells 402, while unpopped grainsremain in their cell 402 until they begin to pop.

It is understood that grain pod insert 401 and grain pod 300, which isdescribed with reference to other figures herein, could also be formedusing extrusion or injection molding. Formable foils can also be used toform grain pod insert 401, with similar benefits to those described withrespect to FIG. 18. For example, cold formable foils, e.g., coldformable aluminum foil, can be used to form grain pod insert 401 andgrain pod 300. Foils can allow for more efficient heat transfer betweenheating element 602 and grains in cells 402. The thickness of the foilcan be chosen such that the force of the popping grain tears the foil,permitting the popped grain to escape through the foil. The use offormable foils can eliminate the need for a bottom cover on grain podinsert 401 or grain pod 300. Grain pod insert 401 and grain pods 300described herein could also be made from thermoforming, aluminumstamping, or other suitable methods of manufacture.

FIG. 19 is a cross-sectional view of a grain pod 300 formed with grainpod insert 401. After it is formed, grain pod insert 401 can be attachedto a sidewall 304 by various methods known in the art. Grain pod 300 asshown in FIG. 19 can also be formed as a single piece using the samemethods detailed with respect to grain pod insert 401, that is, byheating and mechanically manipulating a polymer, or by extrusion orinjection molding. Attaching grain pod insert 401 to a separately formedsidewall 304 in order to form grain pod 300 allows for a differentmaterial to be used for the sidewall 304. It can be desirable to use astronger and less heat-sensitive material for the sidewall 304, which issubject to forces during shipping and user manipulation that grain podinsert 401 may not experience. FIG. 20 is a top perspective view of thegrain pod 300 described with respect to FIGS. 18 and 19. As noted above,grain pod insert 401 may be formed separately and attached to sidewall304, or the entire grain pod 300 can be formed as a single unit. Asshown in FIG. 20, grain pod 300 can include a tab 2001 formed with orattached to sidewall 304. Tab 2001 facilitates user handling of grainpod 300.

FIG. 21 illustrates grain pod 300 as described with respect to FIGS.18-20 with a heating element 602. As shown, heating element 602 hasprotrusions 2101 extending from its bottom surface. Protrusions 2101provide targeted heating to cells 302. Preferably, protrusions 2101match the cross-sectional shape of cells 402, here, a circular shape. Inaddition, protrusions 2101 are arranged on heating element 602 suchthat, when grain pod 300 is positioned in a pod dock, described herein,protrusions 2101 are positioned so that each protrusion 2101 is centeredon a cell 402, thereby providing targeted heat to the opening at the topof each cell 402. In operation, heating element 602 can be mechanicallylowered onto the top of grain pod 300 so that protrusions 2101 pressdown onto top cover 302 (not shown). Heating element 602 and grain pod300 can also be held together by applying a vacuum, thereby ensuring afirm seal. The portions of top cover 302 directly above each cell 402can be formed to depress into the cell 402 as the protrusions 2101 onheating element 602 apply pressure to top cover 302. This provides morefocused and direct heat transfer from heating element 602 because heatis applied in closer proximity to the grains and cooking medium in eachcell 402. The contents of cells 402 can also be vacuum sealed, so thatheat from protrusions 2101 transfers directly through top cover 302 andis applied directly to the grains and cooking medium in the cells 402.

FIG. 22 illustrates heating element 602 positioned above grain pod 300,with the top cover 302 covering the top of cells 402. However, heatingelement 602 with protrusions can also be positioned below grain pod 300,and two heating elements, one positioned above and one positioned belowthe grain pod 300, can be used, with one or both having protrusions orcavities.

Instead of protrusions extending from the main body of heating element602, as depicted in FIG. 21, a plurality of separate, unconnected,heating elements can be used. For example, each protrusion 2101 could bea separate heating element, such that each cell 402 can be heated by anindividually-controllable heating element. Such an array of heatingelements allows for pinpoint heating control depending on variables suchas position of the cell 402 in the cell array. For example, cells 402 onthe interior of grain pod 300 may heat faster than cells 402 on theperiphery of grain pod 300 when the heating element 602 and grain pod300 are arranged horizontally inside grain popping machine 100. Usingindividually-controllable heating elements allows more control oftemperature distribution. For example, the temperature of eachindividual heating element can be pre-programmed to vary during eachpopping cycle such that the grains in interior cells are heating atroughly the same rate and to roughly the same temperature as the grainin peripheral cells, helping to ensure even popping and prevent burningof the grains. Similarly, the plurality of individual heating elementscan each be formed with a cavity, as with the unitary heating elementwith cavities described above with respect to FIG. 6. In suchconfigurations, the cavities can be formed to roughly approximate theshape of cells 402 such that each cell 402 is at least partially insidea cavity during the popping process.

FIG. 23 illustrates a grain pod 300 formed from a metal. Preferablygrain pod 300 is formed of a malleable metal foil, for example, aluminumfoil, copper foil, or tin foil, though other foldable metals and metalfoils can be used. The cells 402 of this grain pod 300 are formed asseparate pockets of the same material, each made to receive one grain.Cells 402 are independent of each other, and each is preferably formedby folding or forming a single piece of foil into a shape that issufficient to hold a single grain. The single piece of foil used to formeach cell 402 is preferably circular in shape, though by overlappingportions of the piece of foil the desired cell shape and dimensions canbe achieved by folding a sheet of foil that was originally other shapes,e.g., rectangular, square, polygonal, triangular, etc. Cells 402 can beformed by using a press and mold, whereby pressure on the piece of foilaround the pre-formed mold causes the foil to bend around the mold intothe desired shape. While FIG. 23 illustrates cells 402 in a roughlyconical shape, cells 402 can be formed in a variety of shapes consistentwith the purposes of grain popping machine 100. The cells can be more orless rounded at the lower ends thereof compared to cells 402 asillustrated in FIG. 23. For example, cells 402 could be squared off atthe bottom thereof, or could be formed in a semi-sphere shape. Moreover,while cells 402 as shown in FIG. 23 are circular in horizontalcross-section, they can be formed with a square, rectangle, or polygonalcross-section or any other cross-sectional shape and dimension discussedherein with respect to other grain pod forms. The foil forming cells 402is selected such that the force of a grain expanding inside each cell402 is sufficient to tear the foil open, allowing the grain to escape asor immediately before it pops.

During assembly, the individual cells 402 shown in FIG. 23 are placedinto a docking tray 2304. Openings 2305 are formed in docking tray 2304.Each opening 2305 is sized to receive a cell 402. Preferably, thehorizontal cross-sectional diameter of cells 402 increases from thebottom portion 2308 to lip 2302 of the cell such that an entire cell 402cannot pass fully through the opening 2305, but instead hangs fromdocking tray 2304. Lip 2302 of cell 402 can have a larger diameter thanthe body of cell 402 so that when cell 402 is placed through opening2305 bottom first, the lip rests on the top surface 2402 of docking tray2304, as shown in FIG. 24. Lip 2302 can be sealed or attached to the topsurface 2402, which is also preferably formed of a metal, e.g., aluminumfoil, by a variety of methods described elsewhere herein. In additionto, or instead of, attaching lip 2302 to top surface 2402, a separatesealing sheet 2306 can be used to sandwich lips 2302 between dockingtray 2304 and sealing sheet 2306. Sealing sheet 2306, which is alsopreferably formed of a metal, e.g., aluminum foil, can be attached tolips 2302 or docking tray 2304, or both, by a variety of methodsdescribed elsewhere herein. Sealing sheet 2306 can be formed withopenings 2307 corresponding to openings 2305 on docking tray 2304. Grainpod 300, as shown in FIG. 23, can also be formed without sealing sheet2306. A top cover, which is also preferably formed of a metal, e.g.,aluminum foil, is attached to sealing sheet 2306 or directly to dockingtray 2304, and functions in the manner described herein with respect toother top covers for grain pods 300 described herein. Sheets 3102 formedof high temperature pressure sensitive adhesive, for example, acrylicadhesives, silicone, or other high temperature adhesives, can be used toattach the various layers of metal, e.g., aluminum, together, as shownin FIG. 31. High temperature pressure sensitive adhesive sheets 3102 canalso be used to attach metal layers in the other grain pods describedherein.

FIG. 24 illustrates a top view of docking tray 2304 as described withreference to FIG. 23. As shown in FIG. 24, lips 2302 of formed cells 402rest on the top surface of docking tray 2304. Lips 2302 can be attachedto docking tray 2304 by friction welding, including horizontal frictionwelding, sonic welding, radio frequency (RF) welding, application ofheat, horizontal scrubbing, gluing, folding connecting taps, orspindling, among other methods known in the art, can be used. Asdiscussed above with reference to FIG. 23, a sealing sheet 2306 or topcover 302 can be used instead of or in addition to direct attachment oflips 2302 to docking tray 2304. FIG. 25 is a side view of grain pod 300as described with reference to FIGS. 23 and 24. As shown in FIG. 25,individual cells 402 hand from docking tray 2304.

FIG. 26 illustrates a clamshell type grain pod 2600. As shown in FIG.26, top cover 2601 is attached to the top surface of tray 2604 along oneside. Cells 2602 are formed or provided in tray 2604 according to any ofthe various methods described herein, and grain pod 2600 can be formedof any of the various materials discussed herein with reference to otherfigures. For example, cells 2602 could be formed integrally with tray2604 or could be individual pod cells as described herein with referenceto FIGS. 23-25. The clamshell design of grain pod 2600 facilitatesmanufacturing by simplifying the process of sealing top cover 2601 tothe top surface of tray 2604.

FIG. 27 illustrates a grain pod 2700. As shown in FIG. 2, grain pod 2700includes a top cover 2701, cells 2702, which are formed or provided intray 2704 according to any of the various methods described herein.Grain pod 2700 can be formed of any of the various materials discussedherein with reference to other figures. For example, cells 2702 could beformed integrally with tray 2704 or could be individual pod cells asdescribed herein with reference to FIGS. 23-25. Cells 2702 are fullycylindrical in construction, with approximately the same diameter fromtop to bottom of each cell. Cells 2702 can be manufactured by formingthe cylindrical walls 2703 out of one piece of material and then fixingan end cap 2705 to one end of the cylindrical walls 2703 to close offthat end.

FIG. 28 illustrates a half shell type grain pod 2800. As shown in FIG.28, grain pod 2800 is formed of a top piece 2801 and bottom piece 2804.Unlike most of the other grain pods described herein, which have fullcells formed or affixed to a tray, the cells of grain pod 2800 areformed when top piece 2801 is attached to bottom piece 2804. Each pieceis formed with a plurality of partial cells 2806 that align withcorresponding partial cells 2806 on the other piece such that when toppiece 2801 is aligned with and affixed to bottom piece 2804, a pluralityof cells are formed, each large enough to receive a grain, flavoring,and a cooking medium. In manufacture, a grain is placed in each of thepartial cells of bottom piece 2804 along with flavoring and a cookingmedium, and then top piece 2801 is affixed to bottom piece 2804 toenclose the grain, flavoring, and cooking medium and form a full cell.At the time when top piece 2801 is affixed to bottom piece 2804, grains2807 can be protruding from partial cells 2806 in bottom piece 2804, asshown in FIG. 29. FIG. 30 shows a side view of an assembled grain pod2800, in which top piece 2801 has been affixed to bottom piece 2806,thereby creating full cells 3002 composed of partial cells 2806 fromeach of top piece 2801 and bottom piece 2804. As illustrated in FIGS.28-30, each full cell 3002 is comprised of two evenly sized partialcells 2806, one from bottom piece 2804 and one from top piece 2801,hence the reference to a half shell grain pod. However, it is understoodthat the size and volume of partial cells 2806 on bottom piece 2804 canbe larger or smaller than the size and volume, respectively, of partialcells 2806 on top piece 2801. For example, partial cells 2806 formed inbottom piece 2804 could form three quarters of the full volume of eachfull cell 3002. It is also understood that full cells 3002 can be formedin a variety of shapes and dimensions, as described herein withreference to other grain pods. It is also understood that bottom piece2804 and top piece 2801 can be formed from any of the materialsdisclosed herein for forming the various described grain pods, and canbe affixed to each using the various methods described herein withrespect to other grain pods. For example, partial cells 2806 can beformed separately from aluminum or other foils and then attached tobottom piece 2804 and top piece 2801.

FIG. 32 illustrates a partial grain pod 3200. As with other grain podsdescribed herein, partial grain pod 3200 includes a plurality of cells402 adapted to receive grains, flavoring, and a cooking medium. Inpartial grain pod 3200, cells are formed by creating a grid 3202 of ametal material, preferably aluminum foil. Grid 3202 is formed by cuttingthe foil into strips and folding the strips to form walls that, whencombined with other strips to form a generally honeycomb shape as shownin FIG. 32, form cells 402. A bottom cover 306 closes off the bottom ofcells 402, and a top cover, not shown, closes off the top of cells 402.Grid 3202 can be formed from other materials instead of metals. Forexample, grid 3202 can be formed of paper-based materials, plastics,etc. Bottom cover 306 and any top cover provided with partial grain pod3200 can be formed of any of the materials disclosed herein withreference to other grain pods, and can be formed of a different materialthan grid 3202.

FIG. 33 shows grain-popping machine 3300 similar the grain poppingmachine shown in FIG. 7, but with a different heating system. Instead ofheating element 102, grain-popping machine 3300 uses a heating chamber3302 to apply heat to grain pod 3301. Grain pod 3301 can be insertedinto grain-popping machine 3300 in a variety of ways, as describedpreviously. Grain pod 3301 can be inserted into grain-popping machine3300 such that the majority of grain pod 3301 is positioned insideheating chamber 3302 and only, or substantially only, a bottom cover3306 of grain pod 3301 extends from the bottom of heating chamber 3302.Grain pod 3301 can include lips 3308 that contact the lower exteriorsurface 3310 of heating chamber 3302. Such a construction aids inpreventing energy from escaping heating chamber 3302 during the poppingprocess.

Lower exterior surface 3310 of heating chamber 3302 can be formed withholes sized to receive cells 402, such that each cell 402 extendsthrough an individual hole in the lower exterior surface 3310 instead ofall cells 420 extending into heating chamber 3302 through a single largeopening. For example, grain pod 3301 can be formed in the mannerdescribed with respect to FIGS. 23 and 24 herein. Docking tray 2304 canbe inserted into grain popping machine 3300 such that each cell 402 isdisposed completely, or substantially completely, inside heating chamber3302, with only the surface of the docking tray 2304 being positionedoutside heating chamber 3302. In this manner, energy is applied evenlythroughout each cell 402 during the cooking cycle. Grain pod 3301 canalso be formed consistent with other grain pods described herein. Inaddition to faster and more even heating, the use of heating chamber3302 with the described hearing methods results in a pod surface that iscooler to the touch and therefore safer for consumers. Grain pod 3301can be mated with heating chamber 3302 using a variety of mechanisms,both automated and manual, as described herein with reference to otherconstructions of grain popping machines.

Heating chamber 3302 can be heated by a variety of heat sources. Forexample, a resistive heating source, also known as a Joule or Ohmicheating, can be used. The heating source can also be electromagnetic,radio frequency, inductive, microwave, or dielectric heating. Theseheating sources can heat kernels 3307 to the required poppingtemperature faster than other heat sources and can also provide moreeven heating of grains 3307. These heating sources can be locatedexternal to heating chamber 3302, and a variety of methods can be usedto transmit energy from the heating sources into heating chamber 3302.For example, energy from the sources can be transmitted into heatingchamber 3302 by mechanical waveguide, antenna, or electrodes. Ifelectrodes are used, they can be positioned in parallel or not inparallel.

As heating chamber 3302 heats the grains inside grain pod 3301 to atarget temperature for a prolonged time, both of which vary depending onthe type of grain used, flavoring, cooking medium, and otherenvironmental conditions such as pressure and altitude, the grains popand the popping of the grains causes them to eject from the bottom ofgrain pod 3301 through its bottom cover, out of upper chamber 102, andinto receiver 104. As detailed above with respect to FIG. 1, the cookedgrains exit upper chamber 102 through outlet 105, which is open to thebottom of grain pod 3301. The described method will eliminate or greatlyreduce the possibility of burning the grain before the completion thecooking cycle.

Systems, methods and apparatus are provided herein. References to“preferred embodiments,” “another embodiment,” “one embodiment,” “anembodiment,” “an example embodiment,” etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may not necessarily include theparticular feature, structure, or characteristic. Moreover, such phrasesare not necessarily referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art to affect such feature, structure,or characteristic in connection with other embodiments, whether or notexplicitly described. After reading the description, it will be apparentto one skilled in the relevant art how to implement the disclosure inalternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element is intended to invoke 35 U.S.C. 112(f)unless the element is expressly recited using the phrase “means for.” Asused herein, the terms “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus.

The invention claimed is:
 1. A grain popping system comprising: ahousing, wherein the housing is at least partially enclosed to define aninterior space, and wherein the housing comprises a top and a bottom; aheating chamber positioned in the interior space, the heating chamberhaving a top and a bottom, and wherein the bottom of the heating chamberis positioned toward the bottom of the housing and the top of theheating chamber is positioned toward the top of the housing; a grain podcomprising a cell having an open end and a closed end, the cellcontaining one or more grains, wherein the grain pod has a bottom coverthat seals the open end of the cell when attached to the grain pod;wherein a hole is formed through the bottom of the heating chamber, andwherein the hole is adapted to receive the cell therethrough, whereinthe bottom cover of the grain pod faces the bottom of the housing whenthe cell is positioned in the bottom of the heating chamber, whereinheating the grain pod heats the one or more grains in the cell, therebycausing the one or more grains to exit the grain pod by piercing thebottom cover of the grain pod.
 2. The grain popping system of claim 1,wherein, when the cell is positioned through the hole in the bottom ofthe heating chamber, the bottom cover of the grain pod is positionedoutside the heating chamber.
 3. The grain popping system of claim 1,wherein the grain pod comprises a plurality of cells.
 4. The grainpopping system of claim 3, wherein a plurality of holes are formedthrough the bottom of the heating chamber, and wherein each of theplurality of holes is adapted to receive one of the plurality of thecells therethrough.
 5. The grain popping system of claim 4, wherein,when the plurality of cells are positioned through the plurality ofholes in the bottom of the heating chamber, the bottom cover of thegrain pod is positioned outside the heating chamber.
 6. The grainpopping system of claim 1, wherein the cell is individually formed,wherein the cell is defined by cell walls having a top edge and a bottomedge, the cell having a first width between the top edge of the cellwalls and a second width between the bottom edge of the cell walls. 7.The grain popping system of claim 6, wherein the grain pod furthercomprises a docking tray and a plurality of individually formed cells,and wherein the individually formed cells are attached to the dockingtray in an array.
 8. The grain popping system of claim 7, wherein aplurality of holes are formed through the bottom of the heating chamber,and wherein each of the plurality of holes is adapted to receive one ofthe plurality of individually formed cells therethrough.
 9. The grainpopping system of claim 8, wherein, when the plurality of individuallyformed cells are positioned through the plurality of holes in the bottomof the heating chamber, the docking tray is positioned outside theheating chamber.
 10. The grain popping system of claim 5, wherein theplurality of cells are formed from a metal foil or an aluminum foil.